Dave, that's good thread, but I think Mike is more concerned with the Titanium inserts that pallet manufacturers often use to overcome sh*tty designs - like the ones where they put a Through-hole 2mm away from a SMT pad. He's not so concerned about the pallet material itself (Duropol, Durastone, etc...) Titanium will allow a thin enough wall thickness to achieve masking the SMD's.

I don't see Titanium being an issue with Lead-Free. Titanium is a non-wettable metal to begin with, and any type of solder will not adhere to it. They do require a lot more maintenance from the solder balls that get stuck in the titanium pockets.

A couple of pallet mfgrs. whom I know do this type of stuff: Ascentec Engineering & Pentagon EMS. Try calling them to find out type of Titanium and compatability with lead-free.

Glastic is cheaper than the custom composite materials normally used for pallets, but the few I have had fabbed started to degrade pretty quickly. Some pallet material is rated at 260 C continuous / 360 Max where the best Glastic I could find is rated at 210 Max.